A hybrid approach for measurement thickness of complex structural parts using ultrasonic inspection and on-machine probing

Zhao, Zhengcai; Ding, Dawei; Fu, Yucan; Xu, Jianming; Han, Jielong

doi:10.1007/s00170-019-04025-1

Cited by 19 publications

(4 citation statements)

References 21 publications

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“…Furthermore, the digital model is used to locate the ultrasonic testing reference point of the regular shape workpiece, and the automatic control of the ultrasonic testing of the robotic arm is finally realized. Zhao et al [3] used tooling fixtures to fix the workpiece to be inspected, and based on the mathematical representation method of the workpiece geometry and model, realized the positioning of the workpiece to be inspected datum point on the CNC machine tool. Abdallah et al [4] used the information in the CAD model of the part to perform offline programming to detect defects in aviation machinery parts and check whether all subcomponents were installed correctly.…”

Section: Introductionmentioning

confidence: 99%

A Point Cloud-Based Feature Recognition and Path Planning Method

Chen

Wang

Huang

2022

Shock and Vibration

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Based on the research background of in situ automatic ultrasonic phased array inspection of irregular porous castings, due to the limited in situ inspection stations, complex shape of irregular porous castings, and extreme multireflection structural features, it is necessary to identify the positioning inspection features among multiple features to be inspected and plan the optimal inspection path. This research is interested in the porous location recognition and its detection path planning of irregular porous castings. For this, a point cloud-based multifeature contour recognition and location algorithm were proposed to simultaneously extract and locate the hole feature and cylindrical feature from an irregular porous castings. Furthermore, a detection path planning method was put forward to search the shortest robot’s detection path based on the above acquired features by visual recognition and positioning technology. First, through the calibration of the industrial robot tool coordinate system and the internal and external parameters of the camera, the “EyeinHand” hand-eye conversion relationship was established. Second, the robot vision system collects the point cloud information of the area to be inspected and performs point cloud splicing, the accuracy of the original data, the removal of noise such as invalid points, outliers and internal noise points, on this basis, the boundary curve of the hole to be inspected was extracted, the cylindrical equation was fitted, its geometric center was calculated, and the central coordinates and axis direction of the contour of the hole to be inspected were obtained. Finally, all the detection paths were traversed through the multibranch tree to obtain the optimal detection path of the detection points of multiple targets. The experimental results show that the positioning accuracy of the feature of the hole to be inspected by the vision system is 0.107 mm, the aperture extraction accuracy is 0.002 mm, the cylinder fitting accuracy is 0.04 mm, and the calculation accuracy of the angle between the two axes is within 0.4. When the number of features to be inspected is different, the average moving distance can be saved by 10.7% by using the end effector after path optimization. The feasibility of in situ automatic ultrasonic phased array detection for irregular porous castings using by visual positioning is verified.

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Section: Introductionmentioning

confidence: 99%

A Point Cloud-Based Feature Recognition and Path Planning Method

Chen

Wang

Huang

2022

Shock and Vibration

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“…Moreover, for non-contact measurement methods, the improvement of measurement accuracy will place higher requirements on the hardware of the entire system, leading to a higher cost [20] and the calibration process is also complicated [21][22][23]. For contact measurement methods, on machine measurement methods were always carried out with touch probes which have low repeatability [14,15], the measuring efficiency is usually low [24], and may easily damage the surface. Regardless of the measurement methods, the temperature disturbance on the measuring instrument cannot be ignored, especially for the high-precision measurement process.…”

Section: Introductionmentioning

confidence: 99%

On-machine measurement and temperature compensation method of NURBS surface interpolation for semicircular narrow neck thickness based on ultra-precision machine tool

Jin¹,

Gao²,

Li³

et al. 2022

Meas. Sci. Technol.

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Flexible joint is a typical low-rigidity micro part, which has four narrow neck structures evenly distributed around its central axis. In the ultra-precision machining process, It is crucial to control the dimensional accuracy of the narrow necks to improve stiffness consistency. However, the limited space of the neck structures and the high accuracy requirements bring extremely difficulties to the measuring process. In this paper, a novel on-machine measurement method for the semicircular narrow necks was presented and a measuring device was developed based on the combination of high linearity incremental measurement method and on-machine measurement technology. Moreover, the uncertainty of measurement error was analyzed in detail. In view of the measurement error caused by temperature drift, a compensation method based on non-uniform rational B-spline (NURBS) surface interpolation was used to enhance the measurement accuracy. The experimental results showed that the measurement accuracy enhanced over 30% after compensation, which met the measuring requirement of flexible joint.

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“…未定义书签。 , [21][22] . For contact measurement method, the touch trigger usually runs at a lower scanning speed, and the presence of contact force makes them unsuitable for measuring super smooth and soft surfaces, leading to a low measuring efficiency [23] .At the same time, sensors suitable for contact measurement methods such as inductive sensors will have different linearity in different ranges, and the instability of the measurement process and the manufacturing errors of the fixtures will also affect the measurement accuracy.…”

Section: Introductionmentioning

confidence: 99%

On-machine measurement and error analysis for narrow neck thickness based on ultra-precision machine tool

Jin

Gao

et al. 2021

Preprint

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As flexible joint is a typical low-rigidity micro part, which have four narrow neck structures evenly distributed around its central axis, it is necessary to strictly control the dimensional accuracy of the narrow necks to improve the consistency of stiffness. However, the radius of the arc of the narrow necks is less than 2mm , and the thickness of thinnest part of the necks formed by two adjacent arcs is only tens of microns, which also has sub-micron accuracy requirement. These cross-scale dimensional characteristics and accuracy requirements give rise to extremely difficulty on the measuring process. In this paper, an on-machine measurement method for the semicircular narrow necks was presented and a measuring device was developed based on the comparative principle by making full use of the high linearity characteristic in the small measuring range of the sensor probes. Meanwhile, the on-machine measurement process based on ultra-precision machine tools was also introduced in details. The experiments results show that the measurement error of the method proposed is less than 0.2 µm , and the repeatability is less than 0.1 μm , which meet the measuring requirement of flexible joint. Furthermore, the theoretical error and the uncertainty caused by probe position, measurement force, environmental factor and the accuracy of the sensor was analyzed, which could provide further evidences to improve the measuring accuracy of micro-scale hybrid surface texture.

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A hybrid approach for measurement thickness of complex structural parts using ultrasonic inspection and on-machine probing

Cited by 19 publications

References 21 publications

A Point Cloud-Based Feature Recognition and Path Planning Method

A Point Cloud-Based Feature Recognition and Path Planning Method

On-machine measurement and temperature compensation method of NURBS surface interpolation for semicircular narrow neck thickness based on ultra-precision machine tool

On-machine measurement and error analysis for narrow neck thickness based on ultra-precision machine tool

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